removing alternator with stripped starter clutch

Albrecht and others,

Sorry if I seem thick, but I am very confused! However I am slowly
starting to understand this better.
These are all good suggestions for stopping the crankshaft from
turning, but that is not the problem. The problem is that the
alternator just spins independently of the crankshaft.

The transmission is in gear, and the crankshaft is not turning. The
alternator still spins freely on its shaft, along with the starter
clutch. If I try to torque the alternator rotor bolt, it just spins
freely. The crankshaft doesn't turn at all.

So it appears that either a) the alternator driven sprocket is
(contrary to Albrecht's knowlege) connected to the alternator shaft
via the sprag clutch or b) the alternator drive chain is broken (or
for some other reason not driving the alternator).

Any thoughts?
 >> Stay informed about: removing alternator with stripped starter clutch 

Albrecht and others,

Sorry if I seem thick, but I am very confused! However I am slowly
starting to understand this better.
These are all good suggestions for stopping the crankshaft from
turning, but that is not the problem. The problem is that the
alternator just spins independently of the crankshaft.

The transmission is in gear, and the crankshaft is not turning. The
alternator still spins freely on its shaft, along with the starter
clutch. If I try to torque the alternator rotor bolt, it just spins
freely. The crankshaft doesn't turn at all.

So it appears that either a) the alternator driven sprocket is
(contrary to Albrecht's knowlege) connected to the alternator shaft
via the sprag clutch or b) the alternator drive chain is broken (or
for some other reason not driving the alternator).

Any thoughts?
 >> Stay informed about: removing alternator with stripped starter clutch 

I don't know why that posted three times, sorry about that.
 >> Stay informed about: removing alternator with stripped starter clutch 

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 >> Stay informed about: removing alternator with stripped starter clutch 

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 >> Stay informed about: removing alternator with stripped starter clutch 

On Wed, 03 Oct 2007 15:33:55 GMT, paul c <toledobythesea DeleteThis @ooyah.ac> wrote:

>a tip on another group mentioned that the rear axle can be used as
>a substitute for the factory puller.

To keep the crankshaft from turning without damaging anything, remove a spark
plug and stuff that cylinder full of 1/4" cord. Just leave the end sticking out
and you can remove it once you get the bolt out.

Making sure that cylinder is on the bottom of the power stroke eliminates the
possibility of warping valves.

--
Jack
 >> Stay informed about: removing alternator with stripped starter clutch 

Andy wrote:

>
Problem is I cannot get any torque on the central bolt that
>holds the alternator onto the alternator shaft, because the shaft
>turns freely (due to the faulty starter clutch).

I don't think that has anything to do with the starter clutch.

The sprag clutch is supposed to turn the alternator shaft, but only when the
starter turns the big idler gear. It is never supposed to stop the alternator
shaft at any time.

A chain connects the crankshaft to the alternator shaft, and chains are bi-
directional. If you put the transmission in gear and prevent the crankshaft
from turning, you should be able to loosen the single bolt that holds the
alternator from rotating.

Since you have the engine out of the frame, you might try wrapping the drive
chain around the engine sprocket to keep the countershaft from turning. The
crankshaft won't be able to turn with the transmission in 5th gear and you
holding the chain from moving.

Another way to stop a crankshaft from turning is to remove the clutch cover
and feed a shop towel between the primary gear on the end of the crankshaft
and the big gear on the clutch as you slowly turn the clutch.

You might also consider using an air impact wrench to loosen the alternator
bolt instead of using a breaker bar on it. Hundreds of tiny impacts from the
air impact wrench won't cause the crankshaft to move as much as the high
torque from a breaker bar.

--
Message posted via MotorcycleKB.com
http://www.motorcyclekb.com/Uwe/Forums.aspx/tech/200710/1
 >> Stay informed about: removing alternator with stripped starter clutch 

Andy wrote:

>The transmission is in gear, and the crankshaft is not turning. The
>alternator still spins freely on its shaft, along with the starter
>clutch. If I try to torque the alternator rotor bolt, it just spins
>freely. The crankshaft doesn't turn at all.

Can you grab the alternator cooling fan with something like an oil filter
strap wrench to stop the alternator from turning while you break the bolt
loose with an air impact wrench?

Don't bugger up the sheet metal fan blades, though...

>So it appears that either a) the alternator driven sprocket is
>(contrary to Albrecht's knowlege) connected to the alternator shaft
>via the sprag clutch or b) the alternator drive chain is broken (or
>for some other reason not driving the alternator).

Maybe the nut(13) has come loose, or the circlip(17) has allowed the cam type
shock absorbing mechanism to move out of engagement?

If the alternator drive chain was broken, you would hear a lot of noise as it
ground the sprocket off the crankshaft.

http://houseofmotorcycles.bikebandit.com/partsbandit/ShowSchematic.asp...eptId=1


This drawing isn't done to good drafting practices at all. Maybe the
draftsman was trying to put all that stuff into a limited area.

The outer bearing (23) goes onto alternator shaft (7) first. Then the starter
clutch (3) is supposed to spline onto the alternator shaft. Then the idler
gear (1) and the needle bearing (1 slide onto the alternator shaft.

This is where the drawing starts getting screwed up.

Then the Belleville springs(6) and the cam type shock absorber(4 and 5) slide
over the alternator shaft and the circlip(17) keeps all that stuff from
moving along the shaft.

Then the inner bearing(24) goes onto the shaft and the nut(13) and washer
hold everything together. You can see the smaller diameter threaded part of
the alternator drive shaft.

--
Message posted via MotorcycleKB.com
http://www.motorcyclekb.com/Uwe/Forums.aspx/tech/200710/1
 >> Stay informed about: removing alternator with stripped starter clutch